الصفحة الرئيسية > الأخبار > Cement Plant Conveyor Selection: The Ultimate Guide for Horizontal Conveying of Bulk Materials

Cement Plant Conveyor Selection: The Ultimate Guide for Horizontal Conveying of Bulk Materials

In the cement manufacturing process and across powder handling industries like chemicals and minerals, material handling and bulk material conveying systems are the lifeline of continuous production. Selecting the right industrial conveyor is critical for operational efficiency. For horizontal conveying applications, plant engineers typically evaluate three primary technologies: the ناقل لولبي, the FU Chain Conveyor (also known as En Masse Conveyor), and the Air Slide or Air Gravity Conveyor.

This comprehensive guide provides a detailed comparison chart, cost analysis, and practical selection criteria for bulk material handling. We will analyze their pros and cons, ideal applications in a cement production line, and answer key questions about energy consumption, maintenance cost, and dust control.

Part 1: In-Depth Comparison of Three Main Horizontal Conveyor Types

Choosing between a mechanical conveyor and a pneumatic conveying system starts with understanding their core principles.

1. Screw Conveyor: The Flexible Workhorse

How It Works: A rotating helical screw inside a tube moves material via axial conveying.
Key Advantages & Benefits:
- Wide Application: Excellent for powder conveying, granular materials, and even semi-moist, sticky substances like raw meal.
- Versatile Installation: Suitable for horizontal conveying and inclined conveying up to 20 degrees.
- Lower Upfront Cost: A common choice for budget-friendly projects.
Main Disadvantages & Limitations:
- استهلاك عالي للطاقة: Significant friction leads to higher operating costs.
- Frequent Maintenance: Wear parts like hanger bearings and seals require regular replacement, increasing downtime.
- Limited Length: Not ideal for long-distance conveying (>30m) without complex support.

2. FU Chain Conveyor (Drag Chain Conveyor): The Sealed Powerhouse

How It Works: A moving chain with attached flights drags material through a fully enclosed, dust-tight casing.
Key Advantages & Benefits:
- تشغيل خالي من الغبار: Superior sealing performance ensures pollution control and a clean plant environment.
- موفرة للطاقة: Consumes 30-40% less power than comparable screw conveyors, reducing energy costs.
- Long-Distance Capability: Ideal for cement plant equipment layouts requiring 80-100m runs.
Main Disadvantages & Limitations:
- Material Restrictions: Not for sticky materials or high-temperature feeds without special design.
- High Wear Part Cost: Chain and flight replacement is a major maintenance expense.
- Higher Capital Expenditure (CAPEX).

3. Air Slide / Fluidized Gravity Conveyor: The Low-Maintenance Solution

How It Works: Low-pressure air fluidizes dry powder over a porous deck, allowing it to flow down a slight incline (4-12°).
Key Advantages & Benefits:
- Minimal Maintenance: No moving parts translate to very low maintenance requirements and high equipment reliability.
- Lowest Operating Cost: Extremely low energy consumption powered only by a blower fan.
- Silent & High Capacity: Perfect for dry bulk solids like cement, fly ash, and pulverized materials.
Main Disadvantages & Limitations:
- Installation Constraint: Requires a constant downward slope, impacting plant design.
- Strict Material Requirement: Only for very dry, free-flowing powders. Cannot handle moisture.
- Distance Limit: Economical range is typically under 100m due to height drop needed.

Part 2: Application-Specific Guide for Cement Plant Conveyor Systems

Here is a practical guide for conveyor system design in key areas of your clinker production and cement grinding plant.

1. Raw Material & Raw Mill Section

Handling Clay or Sticky Raw Materials:
- Best Conveyor Choice: Apron Feeder or Shaftless Screw Conveyor.
- Reason: Handles abrasive materials and prevents clogging. Avoid standard screw conveyors.
Raw Meal Distribution to Homogenizing Silo:
- Best Conveyor Choice: Air Slide Conveyor.
- Reason: The most cost-effective and reliable method for silo feeding and multi-point discharge.

2. Kiln & Pyroprocessing Section

Raw Meal Feeding to Preheater/Kiln:
- Best Conveyor Choice: FU Drag Chain Conveyor.
- Reason: Ensures airtight conveying, maintains kiln pressure, and is built for long-distance transport. A industry standard.
Pulverized Coal Conveying (Coal Mill to Burner):
- Mandatory Choice: Explosion-Proof Chain Conveyor.
- Reason: Critical for plant safety and hazardous material handling. Air slides are strictly prohibited.

3. Finish Mill & Cement Handling Section

Cement Transport from Mill to Storage Silos:
- Best Conveyor Choice: Air Gravity Conveyor (Air Slide).
- Reason: Unbeatable for high-capacity conveying with the lowest total cost of ownership over long distances.
Cement Silo Discharge to Packing Plant:
- Best Conveyor Choice: Rotary Valve Feeder + Screw Conveyor.
- Reason: Provides controlled feed rate and handles potential material buildup.

4. Dust Collection & Material Recovery

Conveying Collected Dust (Bag Filter Hoppers):

Best Conveyor Choice: Air Slide.
Reason: Simple, efficient, and low-maintenance for collecting fine powders from multiple points.

Part 3: Decision Matrix & Selection Criteria Summary

Use this table for a quick conveyor comparison based on your project specifications.

Selection Factor	ناقل لولبي	FU Chain Conveyor	Air Slide
نوع المادة	Versatile: Powders, Granules, Semi-Wet materials.	Dry, Free-Flowing Powders. No sticky materials.	Very Dry, Fine Powders only (e.g., cement, fly ash).
Conveying Distance	Short Haul (< 30m).	Medium to Long Haul (30-100m).	Long Distance (up to 100m) if slope available.
Layout & Space	Flexible: Horizontal or Inclined.	Strictly Horizontal.	Must Slope Downward (4-12°). Needs headroom.
Capital Cost (CAPEX)	Lowest.	High.	Medium.
Operating Cost (OPEX)	High (Energy + Maintenance).	Medium (Lower energy, high part cost).	Very Low (Low energy, minimal upkeep).
Dust Emission & Noise	Can leak dust. Moderate noise.	Excellent Containment. Low noise.	Virtually Dust-Free. Silent operation.
الأفضل لـ	Batching plants, short transfers, difficult materials.	Sealed systems, kiln feed, cement silo top distribution.	Large-volume transfer, eco-friendly plants, dust recycling.

Recommendations

Start with Material Analysis: Perform a material characterization test. Moisture content and particle size are the most critical factors.
Perform a Lifecycle Cost Analysis: Calculate Total Cost of Ownership (TCO) over 10 years, including energy savings, maintenance schedules, and spare parts inventory.
Consult with Specialists: Engage with bulk handling equipment suppliers who have cement industry experience. Request case studies and performance data.
Plan for Safety & Compliance: Always prioritize explosion protection (ATEX) for coal and ensure designs meet local environmental regulations for dust.